Battery conditioning apparatus

ABSTRACT

The present invention relates to a battery conditioning apparatus for conditioning a battery. The apparatus includes a pulse generator circuit generating pulses applied to the battery. A loading circuit is separately and independently actuated from the pulse generator circuit to load the battery separately and independently whilst the pulses from the pulse generator circuit are applied to the battery for conditioning. Concurrently applying the pulses to and loading the battery results in improved battery conditioning when compared with known conditioning methods.

The present application is a Continuation of U.S. application Ser. No. 14/349,219, filed May 28, 2014, which is a National Stage of International Patent Application No. PCT/AU2012/001079, filed Sep. 10, 2012, which claims the benefit of AU 201194076, filed Oct. 3, 2011, whose disclosures are hereby incorporated by reference in their entirety into the present distance.

TECHNICAL FIELD

The present invention relates to a battery conditioning apparatus. The present invention has particular, although not exclusive application to automobile batteries.

BACKGROUND

The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

Battery conditioning apparatus' prevent or reverse the accumulation of lead sulphate on the electrodes of a lead-acid battery by generating electrical pulses that are applied to the terminals of the battery. It has been found that such conditioning apparatus' can significantly increase the operating life and efficiency of batteries.

AU 2003249756 discloses a known battery conditioning apparatus including discrete circuit components. Undesirably, this apparatus only yields suitable conditioning performance for a particular battery voltage and therefore multiple models of the apparatus, with different component values, are required to accommodate for corresponding battery voltages.

The preferred embodiment of the present invention provides an improved battery conditioning apparatus.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, there is provided a battery conditioning apparatus for conditioning a battery, the apparatus including:

-   -   a pulse generator circuit generating pulses applied to the         battery; and     -   a loading circuit separately and independently actuated from the         pulse generator circuit to load the battery separately and         independently whilst the pulses from the pulse generator circuit         are applied to the battery for conditioning.

Concurrently applying the pulses to and loading the battery results in improved battery conditioning when compared with known conditioning methods.

Optionally, the separate loading circuit provides a short circuit or virtual short circuit across the battery to facilitate conditioning of the battery. Optionally, the loading circuit periodically loads the battery. Optionally, the loading circuit loads the battery with a duty cycle of less than 1%. Optionally, the loading circuit loads the battery with a duty cycle of less than 0.5%. Optionally, the pulse generator circuit generating pulses with a duty cycle of about 50%.

Optionally, the pulses have a frequency of greater than 1 kHz applied to the battery. Optionally, the pulses have a frequency of less than 10 kHz, and preferably 5 KHz.

Optionally, the pulses are at a fixed frequency. Optionally, the pulse generator circuit includes a pulsing switch to generate the pulses. Optionally, the pulsing switch includes a Field Effect Transistor (FET) switch.

Optionally, the loading circuit includes a loading switch to load the battery. Optionally, the loading switch includes a Field Effect Transistor (FET) switch. Optionally, the loading circuit further includes a diode in series with the loading switch. Optionally, the loading circuit further includes a serpentine etched board resistance.

Optionally, the pulse generator circuit does not include an inductor, relying instead upon the inductance of the battery. Optionally, the concurrently generated pulses sweep between a frequency range.

Optionally, the battery conditioning apparatus further includes a power supply circuit configured to receive power from any vehicle battery rated from 6 to 48V which is the battery being conditioned.

Optionally, the battery conditioning apparatus further includes a processing controller which controls the respective pulse generator and loading circuits, the controller configured to separately and independently control the pulse generator circuit and loading circuit to concurrently apply the pulses to and load the battery.

According to another aspect of the present invention, there is provided a battery conditioning apparatus method for conditioning a battery, the method including:

-   -   applying pulses to the battery; and     -   separately and independently loading the battery whilst applying         the pulses to condition the battery.

The battery conditioning apparatus may further include a power supply circuit for powering the apparatus from any vehicle battery (e.g. rated from 6 to 48V), without the need for different apparatus models to accommodate different battery voltages. The power supply circuit may include a voltage regulator and pre-regulator circuitry connected to the input of the voltage regulator. The pre-regulator circuitry may be configured to restricting the current flowing into the voltage regulator and suppress voltage pulses input to the voltage regulator.

The battery conditioning apparatus may further include a user interface. The user interface may include a selector for selecting between conditional modes for said controlling of the apparatus. The user interface may include a display for displaying a selected mode of operation.

The battery conditioning apparatus may further include a battery voltage sensor circuit for sensing the battery voltage. The conditional modes of operation may relate to the sensed battery voltage.

The concurrently generated pulses and loading of the battery may both be performed at a fixed frequency. The fixed frequency may be between 1 kHz to 10 kHz, and preferably 5 kHz. Alternatively, the concurrently generated pulses and loading of the battery may sweep between 1 kHz to 10 kHz. The duty cycle of the loading of the battery may be based upon the sensed battery voltage.

The loading circuit may provide a short (or virtual short) across the battery. The loading circuit may include a resistance etched on a printed circuit board (PCB) of the apparatus. The controller may be further configured to periodically perform a load test of the battery to ascertain the integrity of the battery. The battery conditioning apparatus may further include a display for displaying the result of the load test.

The pulse generator circuit may not include an inductor, relying instead upon the inductance of the battery.

According to another aspect of the present invention, there is provided a method for conditioning a battery, the method including the step of concurrently applying pulses to and loading the battery.

The method may further include the step of conditionally applying the pulses to and loading the battery using the sensed voltage of the battery.

The method may further include the step of periodically performing a load test of the battery.

According to another aspect of the present invention, there is provided a battery conditioning apparatus for conditioning a battery, the apparatus including a power supply circuit for powering the apparatus from any vehicle battery, without the need for different apparatus models to accommodate different battery voltages.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to the following drawings:

FIGS. 1a through 1c are schematic diagrams of a battery conditioning apparatus in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

According to an embodiment of the present invention, there is provided a battery conditioning apparatus 10 for conditioning a vehicle battery (not shown) coupled to terminals 12 a, 12 b as shown in FIG. 1a . The apparatus 10 includes a pulse generator circuit 14 for generating pulses to be applied to the battery. A high-current loading circuit 16 is also provided for loading the battery. The apparatus 10 further includes a controller 18 for controlling the pulse generator 14 and loading circuit 16 to concurrently apply the pulses to and load the battery which is an improvement over known conditioning methods. A detailed description of the apparatus 10 is provided below.

The battery conditioning apparatus 10 further includes a power supply circuit 20 for powering the apparatus from any battery rated from 6 and 48V, without the need for different apparatus models to accommodate different battery voltages. The power supply circuit 20 includes a voltage regulator U1 and pre-regulator circuitry including zener diodes D2, D3. The pre-regulator circuitry is connected to the input of the voltage regulator U1 and is configured to restrict the current flowing into the voltage regulator U1 to minimise battery current drain. The pre-regulator circuitry also suppresses voltage pulses input to the voltage regulator U1.

The battery conditioning apparatus 10 further includes a user interface 30. The user interface 30 includes a action switch selector S1 for selecting between various conditional modes (i.e. modes 1 to 3 below) for controlling the apparatus 10. The battery conditioning apparatus 10 further includes a battery voltage sensor circuit 32 including voltage divider R2, RA2C for sensing the voltage of the battery and providing feedback via input port 3 of microprocessor U4 of controller 18. The conditional modes of operation relate to the sensed battery voltage.

The user interface 30 also includes a light emitting diode (LED) display for displaying a selected mode of operation of the apparatus 10. The LED display includes three mode LEDs D6 to D8 which are actuated by the controller 18 in accordance with the mode of operation of the apparatus 10 as indicated below:

-   -   Mode 1: controller 18 controls the pulse generator 14 and         loading circuit 16 to concurrently apply the pulses to and load         the battery provided that the sensed battery voltage is above         10.5V (for a 12V vehicle battery). That is, the conditioning         apparatus 10 conditions the vehicle battery all the time unless         the battery is low and needs to be preserved.     -   Mode 2: controller 18 controls the pulse generator 14 and         loading circuit 16 to concurrently apply the pulses to and load         the battery when the sensed battery voltage is between 10.5V and         12.8V (for a 12V vehicle battery). That is, the conditioning         apparatus 10 conditions the battery when the vehicle engine is         not running.     -   Mode 3: controller 18 controls the pulse generator 14 and         loading circuit 16 to concurrently apply the pulses to and load         the battery when the sensed battery voltage is above 12.8V (for         a 12V vehicle battery). That is, the conditioning apparatus 10         conditions the battery when the vehicle engine is running.

The high current loading circuit 16 provides a short (or virtual short) across the battery when the controller 18 actuates field effect transistor (FET) switch Q2. The loading circuit 16 includes a serpentine resistance (not shown) etched on a printed circuit board (PCB) of the apparatus 10. The controller 18 is further configured to actuate the switch Q2 and periodically perform a load test of the battery every twenty-one hours to ascertain the integrity of the battery.

The load test involves actuating switch Q2 for 5 milliseconds and sensing the battery voltage with sensing circuit 32. Load currents through Q2 of approx. 20 Amps and 40 Amps are present in 12V and 24V vehicle battery systems respectively. The load test is a pass if the sensed battery voltage drop during the load test is less than 2 V and is otherwise a fail.

The battery conditioning apparatus 10 further includes a load test display for displaying the result of the load test. The load test display includes a green load test pass LED D9 which the controller 18 illuminates responsive to a load test pass, and a red load test fail LED D5 which the controller 18 illuminates responsive to a load test failure.

During battery conditioning, the concurrently generated pulses and loading of the battery may both be performed at a fixed frequency of between 1 kHz to 10 kHz, and preferably 5 kHz. The duty cycle of the loading of the battery with the loading circuit 16 is based upon the sensed vehicle battery voltage as follows:

Battery voltage Loading circuit duty cycle  6 V and 12 V 0.4% 24 V 0.2% 36 V and 48 V 0.1%

The controller 18 actuates the FET switch Q1 of the pulse generator circuit 14 with a 50% duty cycle. The pulse generator circuit 14 does not include an inductor, and instead relies upon the internal inductance of the battery to generate the pulses applied to the battery.

The concurrent controlling of the pulse generator 14 and loading circuit 16 to concurrently apply the pulses to and load the battery results in a desirable resultant waveform applied to the battery for improved conditioning. By short circuiting the battery with the loading circuit 16, the internal inductance of the battery advantageously causes “kicking back” of the applied pulses which is an improvement over known conditioning methods.

The apparatus 10 includes a resettable fuse F1 (or polyswitch), an external replaceable fuse F2 and up to four internal fuses F3 to F6.

A person skilled in the art will appreciate that many embodiments and variations can be made without departing from the ambit of the present invention.

In one embodiment, the concurrently generated pulses and loading of the battery may continuously sweep between 1 kHz to 10 kHz during conditioning of the battery.

In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. 

1. A battery conditioning apparatus for conditioning a battery, the apparatus including: a pulse generator circuit generating pulses applied to the battery; and a loading circuit separately and independently actuated from the pulse generator circuit to load the battery separately and independently whilst the pulses from the pulse generator circuit are applied to the battery for conditioning.
 2. The battery conditioning apparatus as claimed in claim 1, wherein the separate loading circuit provides a short circuit or virtual short circuit across the battery to facilitate conditioning of the battery.
 3. The battery conditioning apparatus as claimed in claim 1, wherein the loading circuit periodically loads the battery.
 4. The battery conditioning apparatus as claimed in claim 2, wherein the loading circuit loads the battery with a duty cycle of less than 1%.
 5. The battery conditioning apparatus as claimed in claim 4, wherein the loading circuit loads the battery with a duty cycle of less than 0.5%.
 6. The battery conditioning apparatus as claimed in claim 1, wherein the pulse generator circuit generating pulses with a duty cycle of about 50%.
 7. The battery conditioning apparatus as claimed in claim 1, wherein the pulses have a frequency of greater than 1 kHz applied to the battery.
 8. The battery conditioning apparatus as claimed in claim 7, wherein the pulses have a frequency of less than 10 kHz, and preferably 5 KHz.
 9. The battery conditioning apparatus as claimed in claim 1, wherein the pulses are at a fixed frequency.
 10. The battery conditioning apparatus as claimed in claim 1, wherein the pulse generator circuit includes a pulsing switch to generate the pulses.
 11. The battery conditioning apparatus as claimed in claim 10, wherein the pulsing switch includes a Field Effect Transistor (FET) switch.
 12. The battery conditioning apparatus as claimed in claim 1, wherein the loading circuit includes a loading switch to load the battery.
 13. The battery conditioning apparatus as claimed in claim 10, wherein the loading switch includes a Field Effect Transistor (FET) switch.
 14. The battery conditioning apparatus as claimed in claim 10, wherein the loading circuit further includes a diode in series with the loading switch.
 15. The battery conditioning apparatus as claimed in claim 10, wherein the loading circuit further includes a serpentine etched board resistance.
 16. The battery conditioning apparatus as claimed in claim 1, wherein the pulse generator circuit does not include an inductor, relying instead upon the inductance of the battery.
 17. The battery conditioning apparatus as claimed in claim 1, wherein the concurrently generated pulses sweep between a frequency range.
 18. The battery conditioning apparatus as claimed in claim 1, further including a power supply circuit configured to receive power from any vehicle battery rated from 6 to 48V which is the battery being conditioned.
 19. The battery conditioning apparatus as claimed in claim 1, further including a processing controller which controls the respective pulse generator and loading circuits, the controller configured to separately and independently control the pulse generator circuit and loading circuit to concurrently apply the pulses to and load the battery.
 20. A method for conditioning a battery, the method including: applying pulses to the battery; and separately and independently loading the battery whilst applying the pulses to condition the battery. 